Flushness shims

ABSTRACT

A media player according to the invention is provided. The media player may include a scroll wheel and a housing including a retention ledge. The retention ledge may maintain the position of the scroll wheel with respect to the housing. A flexible printed circuit may also be included in the media player. The flexible printed circuit may include a first face and a second face. The first face may contact the scroll wheel. The second face may include tactile dome switches. Compressible shims may also form a portion of the media player and may be adjacent the second face. The compressible shims may control the distance between the scroll wheel and the retention ledge.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of, commonly-assigned U.S. patent application Ser. No. 11/519,284, filed Sep. 11, 2006 now U.S. Pat. No. 7,902,475, which is fully incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

This invention can relate to apparatus and methods for improving the construction of portable media players. More particularly, this invention can relate to maintaining the effectiveness of construction of portable media players across a range of operational conditions.

BACKGROUND OF THE INVENTION

On many portable electronics with tactile button interfaces, there is a need to have the surface of the button as close to flush as possible with the surface of the housing in which it sits. This is exemplified in the current line of iPod™ products made by Apple Computer Inc., of Cupertino, Calif., which have scroll wheel interfaces. Scroll wheel interfaces permit a user to run a finger around the wheel to navigate through menus. Because dome switches beneath the surface of the wheel can be actuated when pushed intentionally by the user, there is an assembly tolerance gap between the dome switch and its actuator.

As a result of this gap, there can be a small amount of “play” in the fit of the wheel to the housing. This “play” can have a negative impact on the feel of the device. It would therefore be desirable to reduce the gap by having the wheel justified toward the face of the product. It would also be desirable to implement this reduction via a separate mechanism from the dome switches beneath the scroll wheel.

In addition, other product designs may be implemented with a silicone sheet directly behind the wheel and the housing. The silicone sheet can help to keep the two planes flush. However a need exists for a more efficient system for maintaining the two planes substantially, consistently flush.

SUMMARY OF THE INVENTION

One embodiment of the invention can be directed to reducing the tolerance gap to a minimum across a predetermined operational range of the device. The tolerance gap exists because the dome switches cannot be pre-compressed when the device is operational. Thus, the design takes into account the largest nub and the lowest dome to provide a tolerance gap which the device can provide such that the dome switches are not pre-compressed in all manufacturing situations. However, the tolerance gap may result in a certain amount of “play” across the range of operation of the invention. Compressible shims or another suitable device according to the invention preferably provide a force that maintains the tolerance gap at a minimum, or at least at a reduced value, across the predetermined operational range of the device.

A media player according to the invention is provided. The media player may include a scroll wheel and a housing, which has a retention ledge. The retention ledge can accurately position the scroll wheel with respect to the housing. The media player may also include compressible shims that control the distance between the scroll wheel and the retention ledge.

In one embodiment of the invention, the scroll wheel may be implemented to actuate, directly or indirectly, dome switches on a flexible printed circuit. The flexible printed circuit may be under, in contact with, or proximal to, the scroll wheel. In this embodiment, the shims should preferably be implemented so as not to affect the operation of the dome switches.

In another embodiment of the invention, at least one or more springs may be implemented instead, or in combination with, the foam shims.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:

FIG. 1 is a perspective view of a media player, in accordance with one embodiment of the present invention;

FIG. 2 is a top plan view of scroll wheel 202 and center button 204 of a media player according to the invention;

FIG. 3 shows a cross-section of the scroll wheel 202, button 204, and housing 206 from Line A-A in FIG. 2 according to the invention;

FIG. 4 shows a cross-section of the scroll wheel 202, button 204, and housing 206 from Line B-B in FIG. 2 according to the invention;

FIG. 5 shows an exploded portion of FIG. 4 taken from curve C in FIG. 4;

FIG. 6 shows an exploded perspective view from below of the flushness shims and related apparatus according to one embodiment of the invention;

FIG. 7 shows an exploded perspective view from above of the flushness shims and related apparatus according to one embodiment of the invention;

FIG. 8 shows one embodiment of a method according to the invention;

FIG. 9 an exploded perspective view from below of a single spring and related apparatus according to one embodiment of the invention; and

FIG. 10 shows an exploded perspective view from above of a plurality of springs and related apparatus according to another embodiment of the invention.

DETAILED DESCRIPTION OF THE DISCLOSURE

The invention can relate to obtaining a substantially coplanar relationship between two surfaces—i.e., a relationship wherein the two surfaces are parallel, within a few degrees, to one another and substantially are part of a single plane—in a media player. In one specific embodiment, the invention may relate to obtaining a substantially coplanar relationship between a scroll wheel in a media player and the housing of the media player. A substantially coplanar relationship may be advantageous to prevent dust from entering the media player and to protect the media player's internal components in other ways, which will be described below.

In one embodiment of the invention, flushness shims, which can be made of a soft foam-like material manufactured by Nitto Denko, of Japan, may be placed in such a way as to exert pressure on the scroll wheel. In one embodiment, the foam is soft enough that the foam does not “deaden” the feel of a dome switch when the foam is partially compressed. In one embodiment, the shims can be symmetrically located (e.g., at 45° locations) around the scroll wheel while the dome switches may, in one embodiment, be placed at the 90° locations. In this way, the foam can only partially compress when the dome switch button is actuated. Also the compression of the foam may act to prevent creep over time.

In one embodiment of the invention, the foam can apply pressure from the under side of the wheel to push the face of the wheel flush with the housing. The foam can be in a pre-compressed state to apply the pressure consistently across the operational range of the media player. The foam manufactured by Nitto, for example, is particularly advantageous for this because it can be compressed to 10% of its non-compressed thickness. The Nitto foam is made in many thicknesses, but an about 1.0 millimeter (mm) thickness can be used for the scroll wheel application that can be nominally—i.e., with no user compression of the wheel—compressed to about 0.65 mm. The about 1.0 mm foam could theoretically be compressed down to as little as about about 0.1 mm (10%). When the dome switch is activated, the foam may get compressed down to about 0.4 mm. The minimum 0.4 mm thickness during activation of the dome switch allows the foam to be in substantially constant compression while preventing wear or creep over time.

The Nitto material was originally designed as an LCM (Liquid Crystal Matrix display) gasket for portable electronics. The Nitto foam is known for its shock-absorbing qualities and ability to keep dust out of a display assembly. It is not essential that the material used for the flushness shims according to the invention be the Nitto material. Rather, any suitable foam having suitable mechanical properties may be used according to the invention.

The following physical characteristics are beneficial in certain shims according to the invention. First, the shims should possess an ability to take a pre-compression without creep. In one embodiment, pre-compression can be sufficient to overcome assembly tolerances with respect to the distance between the scroll wheel and the housing surface. In one iPod™ device, for example, the foam should be able to be pre-compressed to about 0.2 mm to overcome possible factory condition within the part specifications.

The shims may also possess the ability to maintain a substantially constant push-back force. The shims can also include a relatively low compressive force so as not to “deaden” the feel of nearby buttons. In other embodiments, a similar effect as the effect created by the foam shims may be created with a large, soft spring that may be concentric with the wheel or center button. This may be a more complex mechanism, but it is conceivable that it could have the same function. Alternatively, in another embodiment of the invention, the effect created by the foam shims may be obtained by using a plurality of springs which may be used to create the same force and action of the foam.

FIG. 1 is a perspective diagram of media player 100, in accordance with one embodiment of the present invention. The term “media player” generally refers to computing devices that are dedicated to processing media such as audio, video or other images, as for example, music players, game players, video players, video recorders, cameras, and the like. In some cases, the media players contain single functionality (e.g., a media player dedicated to playing music) and in other cases the media players contain multiple functionality (e.g., a media player that plays music, displays video, stores pictures and the like). In either case, these devices are generally portable so as to allow a user to listen to music, play games or video, record video or take pictures wherever the user travels.

In one embodiment, the media player is a hand-held device sized for placement into a pocket of the user. By being pocket sized, the user does not have to directly carry the device and therefore the device can be taken almost anywhere the user travels (e.g., the user is not limited by carrying a large, bulky and often heavy device, as in a laptop or notebook computer). For example, in the case of a music player, a user can use the device while working out at the gym. In case of a camera, a user can use the device while mountain climbing. In the case of a game player, the user can use the device while traveling in a car. Furthermore, the device can be operated by the users' hands; no reference surface such as a desktop is needed. In the illustrated embodiment, media player 100 is a pocket-sized hand-held MP3 music player that allows a user to store a large collection of music. Although used primarily for storing and playing music, the MP3 music player shown herein can also include additional functionality such as storing a calendar and phone lists, storing and playing games, storing photos and the like. In fact, in some cases, it can act as a highly transportable storage device.

Media player 100 can also be any miniature consumer electronic device. Miniature electronic devices may have a form factor that is smaller than that of hand-held devices. Illustrative miniature electronic devices can include, but are not limited to, watches, rings, necklaces, belts, accessories for belts, headsets, accessories for shoes, virtual reality devices, other wearable electronics, accessories for sporting equipment, accessories for fitness equipment, or combinations thereof.

By way of example, the MP3 music player can correspond to the iPod™ MP3 player manufactured by Apple Computer of Cupertino, Calif. One pocket-sized IPod™ has a width of about 2.4 inches, a height of about 4 inches and depths ranging from about 0.72 to about 0.84 inches, although any relatively small size is possible.

As shown in FIG. 1, the media player 100 FIG. 1 also shows housing 102, display screen 104, scroll wheel 110, center button 112, holdswitch 114, and earphone jack 116 of media player. Housing 102 can host center button 112, and can in fact be configured to retain scroll wheel 110 in its position in the media player. Navigation can be implemented in the form of transmission of user instructions in response to user stimulus on scroll wheel 110, button 112, etc.

In addition, housing 102 can also define the shape or form of the media player. That is, the contour of housing 102 can embody the outward physical appearance of media player 100. The integrated circuit chips and other circuitry contained within the housing can include a microprocessor (e.g., CPU), memory (e.g., ROM, RAM), a power supply (e.g., battery), a circuit board, a hard drive, other memory (e.g., flash) and/or various input/output (I/O) support circuitry. The electrical components can also include components for inputting or outputting music or sound such as a microphone, amplifier and a digital signal processor (DSP). The electrical components can also include components for capturing images such as image sensors (e.g., charge coupled device (CCD) or complimentary oxide semiconductor (CMOS)) or optics (e.g., lenses, splitters, filters). The electrical components can also include components for sending and receiving media (e.g., antenna, receiver, transmitter, transceiver, etc.).

In the embodiment shown in FIG. 1, the media player 100 includes display screen 104 and related circuitry. Display screen 104 is used to display a graphical user interface as well as other information to the user (e.g., text, objects, graphics). As shown, display screen 104 is visible to a user of media player 100 through opening 105 in housing 102, and through transparent wall 106 disposed in front of opening 105.

As mentioned above, media player 100 also can include scroll wheel 110. Scroll wheel 110 generally consists of touchable outer surface 111 for receiving a finger or other suitable object for manipulation on scroll wheel 110.

The position of display screen 104 and scroll wheel 110 relative to housing 102 can be widely varied. For example, they can be placed at any external surface (e.g., top, side, front, or back) of housing 102 that is accessible to a user during manipulation of media player 100. In the illustrated embodiment, scroll wheel 110 is located in a lower, front area of housing 102.

In addition to the above, media player 100 can also include one or more buttons 112. Button 112 can be configured to provide one or more dedicated control functions for making selections or issuing commands associated with operating media player 100. In most cases, the button functions are implemented via a mechanical clicking action.

Moreover, the media player 100 can also include hold switch 114, a headphone jack 116 and a data port (not shown).

The methods according to the invention can preferably implemented by a combination of hardware and software, but can also be implemented in hardware or software. The method can also be embodied as computer readable code on a computer readable medium. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, hard drive, flash memory, CD-ROMs, DVDs, magnetic tape, optical data storage devices, and carrier waves.

FIG. 2 shows a top plan view of illustrative scroll wheel 202 and center button 204. FIG. 2 also shows a portion of housing 206. FIG. 2 provides a reference figure for FIGS. 3 and 4 which follow and which show the internal components of the media player shown in FIG. 2.

FIG. 3 shows a cross-section of scroll wheel 202, button 204, and housing 206 from line A-A in FIG. 2. FIG. 3 shows scroll wheel 302, center button 304, dome switch 306, back plate 308, flexible printed circuit board 310, stiffener plate 312, dome actuator 314, and assembly tolerance gap 316.

FIG. 3 also shows a number of exemplary approximate thicknesses according to one embodiment of the invention. The thickness legends have been included in the FIGURE for the sake of clarity. Each of the values shown in FIGS. 3 and 4 are in millimeters (mm). The thicknesses can include (starting from the left and moving towards the right) 0.70 mm for the cosmetic housing thickness, about 0.40 mm for the stiffener plate thickness, about 0.25 mm for the dome actuator height, about 0.12 mm for the assembly tolerance gap which results from the design of how much distance exists from the actuator nubs to the actuator domes in a least tolerant case scenario wherein the nub is as high as product specifications allow and the dome is as low as product specifications allow (if the domes are pre-loaded by the nubs, the switch may be in an ON state even before it is depressed), about 0.28 mm for the dome switch height, about 0.15 mm for the flexible printed circuit (FPC) height, and about 0.65 mm for the scroll wheel thickness. One purpose of pre-compressing the shims is that the pre-compression ensures that the tolerance gap remains consistently at a minimum substantially independent of the operational conditions of the device. In one embodiment of the invention the tolerance gap is transparent to the user.

FIG. 4 shows a side view of a cross-section of scroll wheel 202, button 204, and housing 206 from Line B-B in FIG. 2. FIG. 4 shows in pertinent part flushness shim 401, scroll wheel 402, and FPC 410. The thicknesses shown in FIG. 4 include the thickness of the flushness foam of nominally about 0.65 mm, about 0.15 FPC thickness and about 0.65 wheel thickness.

FIG. 5 shows an exploded portion of FIG. 4 taken from curve C in FIG. 4. FIG. 5 shows retention ledge 502 of the housing surface, wheel surface 504, and point of contact 506 between retention ledge 502 and wheel surface 504. One aspect of the invention can be to maintain the surface of the housing and the surface of the wheel as planar as possible all around the circumference of the wheel across all the operational conditions of the media player.

When the flushness shim is compressed, retention ledge 502 can touch all around the circumference of the scroll wheel. It follows that, in the situation of the flushness shim being compressed, the actual flushness of retention ledge 502 and the scroll wheel can then be controlled by the manufacturing tolerances of the wheel and the housing. This situation can be an optimal set of conditions for achieving one aforementioned goal of the invention—i.e., to maintain the two surfaces as planar as possible all around the circumference of the wheel across all the operational conditions of the media player.

FIG. 6 shows an exploded perspective view from below of the flushness shims and related apparatus according to one embodiment of the invention. FIG. 6 shows housing 602, scroll wheel 604, adhesive 606, retainer 608, adhesive 610, FPC 612, dome switches 614, flushness shim foam pieces 616 and stiffener plate 618.

FIG. 7 shows an exploded perspective view from above of the flushness shims and related apparatus according to one embodiment of the invention. FIG. 7 shows housing 702, scroll wheel 704, adhesive 706, retainer 708, adhesive 710, FPC 712 (dome switches not visible from this perspective), flushness shim foam pieces 716 and stiffener plate 718. Stiffener plate 718 also shows dome switch actuator nubs 720.

A method according to the invention is shown in FIG. 8. Step 810 shows determining two or more surfaces in a portable media player for which a desired relationship may exist—e.g., a substantially coplanar relationship. Step 820 shows placing compressible foam shims, a soft spring or other suitable apparatus having a compressibility such that the desired relationship between the surfaces is obtained (without compromising the other functions of apparatus associated with the surfaces).

Step 830 shows pre-compressing the shims (or spring) in order to maintain the relationship between the two surfaces across a pre-determined operational range of the player. Step 840 shows sealing the device such that the pre-compression of the shims (or spring) can be fixed. It should be noted that at least steps 810, 820, and 840 include optional components relating to the apparatus for implementation of the invention—i.e., shims, a spring, or other suitable apparatus.

FIG. 9 shows one embodiment of the invention having spring 916 implemented as the apparatus for controlling the distance between housing 902 and scroll wheel 904.

FIG. 10 shows that a plurality of small springs 1016 may be implemented instead of the single large spring shown in FIG. 9.

The methods according to the invention can preferably implemented by a combination of hardware and software, but can also be implemented in hardware or software. The method can also be embodied as computer readable code on a computer readable medium. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, hard drive, flash memory, CD-ROMs, DVDs, magnetic tape, optical data storage devices, and carrier waves.

It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention. The embodiments described herein-above are further intended to explain the best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such, or other embodiments and with the various modifications required by the particular applications or uses of the invention.

Accordingly, the description is not intended to limit the invention to the form disclosed herein. Also, it is intended that the appended claims be construed to include alternative embodiments. 

What is claimed is:
 1. A method for obtaining a substantially coplanar relationship between a first and second element of a portable media player, the method comprising: pre-compressing a plurality of foam shims; and placing the plurality of foam shims in the media player, wherein the plurality of foam shims exerts a force on the first element, the force acting to obtain a substantially coplanar relationship between a surface of the first element and a surface of the second element, wherein the two surfaces are exterior surfaces of the portable media player.
 2. The method of claim 1 further comprising: maintaining at least a portion of the force of the plurality of foam shims on the first element across a pre-determined operational range of the media player.
 3. The method of claim 1 further comprising: determining which two elements of the media player would be enhanced by a substantially coplanar relationship.
 4. The method of claim 1 further comprising: sealing the media player; and in response to the sealing, maintaining at least a portion of the force of the plurality of foam shims on the first element across a pre-determined operational range of the media player.
 5. The method of claim 1: wherein, in response to the pre-compression, the compressible foam shims remain in a compressed state in order to provide a force that contributes to maintaining a pre-determined relationship across an operational range of the media player.
 6. The method of claim 5, further comprising: placing the compressible foam shims in the media player.
 7. The method of claim 5, further comprising: sealing the media player during the pre-compressing so that at least a portion of the force is maintained across the operational range of the media player.
 8. The method of claim 5, wherein the force provided by the compressible foam shims is substantially constant across the operational range of the media player.
 9. The method of claim 5, wherein the force provided by the compressible foam shims maintains a tolerance gap at a minimum substantially independent of operational conditions across the operational range of the media player.
 10. The method of claim 5, wherein the pre-determined relationship between the two surfaces is controlled by manufacturing tolerances gap at a minimum substantially independent of operational conditions across the operational range of the media player.
 11. The method of claim 5, wherein the two surfaces are separated by a gap.
 12. The method of claim 5, wherein the operational range of the media player comprises an activation range for a dome switch.
 13. The method of claim 5, wherein the pre-determined relationship comprises a first surface of the two surfaces being substantially flush with a second surface of the two surfaces.
 14. The method of claim 1, wherein the force exerted by the foam shims is substantially constant across a pre-determined operational range of the media player.
 15. The method of claim 1, wherein the force exerted by the foam shims maintains a tolerance gap at a minimum substantially independent of operational conditions across a pre-determined operational range of the media player.
 16. The method of claim 1, wherein the relationship between the two surfaces is controlled by manufacturing tolerances when the foam shims are compressed beyond the pre-compression.
 17. A method for obtaining a pre-determined relationship between two surfaces in a media player, the method comprising: pre-compressing a plurality of compressible foam shims, wherein, in response to the pre-compression, the compressible foam shims provide a force that contributes to maintaining the pre-determined relationship across an operational range of the media player, and wherein: a first surface of the two surfaces is an outer surface of a scroll wheel; and a second surface of the two surfaces is a housing of the media player.
 18. A method for obtaining a substantially coplanar relationship between two surfaces in a portable media player, the method comprising: pre-compressing a plurality of foam shims; and the plurality of foam shims exerts a force on at least one of the two surfaces, the force acting to obtain a substantially coplanar relationship between the two surfaces; the at least one of the two surfaces being an outer surface of a scroll wheel; and another one of the two surfaces being a housing of the media player.
 19. A method for obtaining a substantially flush relationship between a first surface of a first element and a second surface of a second element of a portable electronic device comprising: compressing a plurality of foam shims to a pre-compressed state; and placing the pre-compressed foam shims in the electronic device; wherein the pre-compressed foam shims exert a force on the first element, the force acting to align the first surface substantially flush with the second surface; and the first surface and the second surface are exterior surfaces of the electronic device. 